System and apparatus for assembling an inflatable insulation panel

ABSTRACT

An inflatable or gas-filled insulation panel comprises an envelope having two outer sheets sealed together along edges of the sheets and at least one of the sheets has an outer reflective surface. The envelope encases a plurality of internal films that include a polymeric film having a plurality of reflective stripes disposed thereon and spaced apart on the films. Seals are formed along the gaps or areas between the reflective stripes on the films by application of heat and pressure, which causes the films to seal to each other and the outer sheets at spaced apart intervals. A channel is formed between the outer edges of the films and the outer sheets, and a valve, disposed at an end of the panel, is in fluid communication with the channel for the injection of a fluid, such as an inert gas or air, to inflate panel.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Divisional of U.S. application Ser. No. 12/200,557filed Aug. 28, 2008 now U.S. Pat. No. 8,021,734, which claims thebenefit of U.S. Provisional Application No. 60/968,429 filed Aug. 28,2007, and incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

Embodiments of this invention relate generally to systems and methodsused to insulate an interior of various items such as coolers,refrigerators, containers, automobiles, buildings etc. Morespecifically, embodiments of the invention pertain to the use ofinflatable or gas-filled insulation panels used to insulate such items.

BRIEF DESCRIPTION OF THE INVENTION

An inflatable or gas-filled insulation panel comprises an envelopehaving two outer sheets sealed together along edges of the sheets and atleast one of the sheets has an outer reflective surface. The envelopeencases a plurality of internal films that include a polymeric filmhaving a plurality of reflective stripes disposed thereon and spacedapart on the films. In an embodiment, the outer reflective surface(s)and reflective stripes are composed of an aluminum alloy. The two outersheets may comprise a laminate of a polymeric film and aluminum sheet.Seals are formed along the gaps or areas between the reflective stripeson the films by application of heat and pressure, which causes the filmsto seal to each other and the outer sheets at spaced apart intervals. Achannel is formed between the outer edges of the films and the outersheets, and a valve disposed at an end of the panel is in fluidcommunication with the channel for the injection of a fluid, such as aninert gas or air, to inflate panel.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention can be more easily understood and the furtheradvantages and uses thereof more readily apparent, when considered inview of the following detailed description when read in conjunction withthe following figures, wherein:

FIG. 1A is a perspective view of an embodiment of a reflectivegas-filled insulation panel.

FIG. 1B is a sectional view of the insulation panel take shown in FIG.1.

FIG. 2 is a schematic expanded view of the different layers of materialsmaking up the insulation panel and the alignment of metal stripes.

FIG. 3 is a side schematic view of support platen and heating/sealingdie that is a component of the machine used to make the insulationpanel.

FIGS. 4A-4D illustrate the different step of sealing together thecomponent of the panel.

FIG. 5 is a flow chart describing steps to a method of assembling ormanufacturing an inflatable insulation panel.

FIG. 6 is a bottom view of a platen used in the process of assemblingthe inflatable insulation panel.

FIG. 7 is a top schematic illustration of inflatable insulation panelsbeing assembled.

DETAILED DESCRIPTION OF THE INVENTION

A more particular description of the invention briefly described abovewill be rendered by reference to specific embodiments thereof that areillustrated in the appended drawings. Understanding that these drawingsdepict only typical embodiments of the invention and are not thereforeto be considered to be limiting of its scope, the invention will bedescribed and explained. The term “gas-filled” is used hereininterchangeably with the term “inflatable” and is intended to describe apanel that is inflatable by injection of a fluid such as an inert gas orair, or any other fluid that may be used to inflate the panel to provideinsulation properties.

With respect to FIGS. 1A and 1B there is illustrated an embodiment ofthe invention for a reflective gas-filled insulation panel 10 thatincludes an inflatable aluminum envelope 11 encasing a plurality ofinterior films 12 or layers that are arranged and sealed relative to oneanother and the envelope 11 to form the honeycomb baffle arrangement inFIG. 1B. As shown in these and other drawings, the panel 10 includes agas-filled panel with internal and external reflective surfaces, whereinthe reflective surfaces are aluminum. In an embodiment, there may be atleast one external surface, or one or more external reflective surfaces.

With respect to FIG. 2, the aluminum envelop 11 is composed of twosheets (11A and 11B) of an aluminum laminate material, each sheetcomprises a first layer 30 of aluminum and a second layer 31 of polymerfilms such as polyethylene, which includes a metallocine bonding agentand fire retardant materials. The invention is not limited to the use ofaluminum as a reflective surface, and may incorporate other materials,compounds or formulas for bonding agents and fire retardant materials.The first layer 30 may be approximately within a range of about 0.0003inches to about 0.0007 inches thick aluminum foil. As explained in moredetail, and in reference to certain test results, these thicknesses areintended to meet flammability requirements, retention of expansion, andimproved thermal performance for building requirements.

Note, that in at least one other embodiment the envelope 11 may comprisethe two sheets 11A and 11B with only one or at least one of the sheets,11A and/or 11B having an outer aluminum layer laminated with thepolyethylene. In such a case the other sheet making up the envelope 11may be one or more polymeric layers sealed to the sheet 11A or 11B

The polyethylene second layer 31 is about 0.0025 inches thick grade sothe two sheets 11A and 11B each may have a total thickness ranging fromabout 0.0028 inches to about 0.0032 inches. In addition, thepolyethylene or second layer 31 may have a thickness of about 0.0010inches or greater. The polyethylene films making up the envelope 11,second layer 31 and the interior films 12 is similar in grade andcomposition and is manufactured by Pliant Corporation located inSchaumberg, Ill., or DanaFilms, Inc. located in Franklin, Ky. Note,while reference is made to polyethylene, any impervious polymeric filmmay be used that can accept the below referenced metal stripes andadequately bond to aluminum sheets. The lamination may be sourced outand performed by Cleveland Laminating Corporation.

In an embodiment, the polyethylene or polymeric films may comprise aplurality of polyethylene including seven polymeric films bondedtogether to form a single film, a single nylon film disposed in themiddle of six polyethylene films. The outer two polyethylene films maybe constructed of a cull extruded process and contain the metallocinebonding agent for securing films 12A and 12E to sheets 11A and 11Brespectively. The next two consecutive films are treated with the fireretardant material, so the outer films serve as a barrier betweenaluminum layers 30 and 31 and the fire retardant material, which couldresult in degradation to the aluminum layers 30 and 31 over time. Themiddle nylon film retains air in the panel 10 and/or minimizes oreliminates migration of a fluid (such as air, argon or an inert gas)from the interior of the panel 10.

As shown in FIGS. 1A and 1B seals 18 and 36 are formed by sealingtogether the two sheets 11A and 11B of aluminum laminate along outeredges 23 (longitudinal edge) and 37 (lateral edge) of the envelopeforming one or more interior channels 24 within the panel 10 throughwhich a fluid, preferably a gas such as air or an inert gas, flows toinflate the panel 10. A valve, or in the embodiment shown herein, twovalves 25A and 25B are disposed between the aluminum laminate sheets 11Aand 11B of the envelope 11 for injection of a desired fluid/gas. Theinterior films 12 are sealed together relative to one another and to theenvelope 11, in such a manner that the films 12 and envelope 11 inflateor expand forming the honeycomb baffle arrangement as a fluid is pumpedinto the panel 10 and flows through channels 24.

The interior films 12A-12E are illustrated in more detail in FIG. 2 andinclude a polymeric film 26 such as polyethylene, as described above,that has been “metalized.” That is, a plurality of metal stripes 15metalized to the film 26 and spaced apart on the film 26. The preferredmetal is an aluminum alloy and formed as 0.75 inch wide stripes andspaced apart about 0.25 inches on the film 12. The metalization processcan be performed by Rolvac located in Dayville, Conn.

As shown in FIG. 2, during an assembly process, the interior films12A-12E are positioned relative to one another so a metal stripe 15, forexample on film 12B, is aligned with a gap 27 positioned between metalstripes 15 on film 12A and 12C. This is done so that when the films aresealed together, the portions of the films 12A-12E without the metal, orthe gaps 27 adhere together, and the metal stripes 15 do not adhere tothe polyethylene. The dashed lines 28 represent points or areas wherethe films 12A-12E adhere to one another and to the envelope 11. Withthis arrangement fluid/gas is allowed to penetrate between theconsecutive films 12A-12E and envelope 11 allowing the panel to inflate.

As illustrated, film 12A is positioned with the metal stripes 15 facingthe aluminum sheet 11A, and the film 12B, and all films 12C, 12D and 12Eare positioned with the metal stripes 15 positioned facing the aluminumsheet 11B. Therefore the polyethylene 26 of the films 12A and 12B abutone another and may fuse together during the assembly process, and byinspection there may appear only four interior films. Accordingly, inreference to FIG. 1B, film 12 adjacent 11A appears a single film, butmay indeed be a fusion of two films 12A and 12B. In addition, with film12A disposed in this position relative to sheet 11A, the film 12Aseparates from sheet 11A as the envelope inflates. While theabove-described invention pertains to an embodiment having five internalfilms, the invention is not so limited and may contain even a singleinterior film or more than five films.

An assembly machine used to assemble the panel 10 is illustrated anddescribed in U.S. Pat. No. 6,755,568, which is incorporated herein andmanufactured by Convertec a/k/a NuLine Mfg., Corp. located in Denver,Colo. The number of rolls of materials mounted on the machine depends onthe number of sheets or layers used to make the panels 10. Theembodiments described herein include seven layers of materials, so ofcourse seven rolls of material are needed. The size of the panel 10 mayalso dictate the width of the rolls of materials. For example in aninsulation panel used in building construction, the panels 10 assembledand cut into sections up to seventy inches long and fifteen to eighteeninch wide panels. However, embodiments of the invention are not limitedto these dimensions as panel sections of various lengths and widths maybe used for building construction and other applications.

During the assembly process the seals are formed at four differentstations or at four different times. With reference to FIG. 4A-4D, thereare schematically illustrated four stages of the sealing assembly. InFIGS. 4A and 4B, a smaller rectangle represents the five interior films12A-12E placed on top of or above the polymeric film 26 of the firstaluminum laminate sheet 11A of the envelope 11. As shown, the films12A-12E may be cut during or before assembly to have dimensions smallerthan that of first aluminum sheet 11A. By way of example, for a panel 10having an envelope width dimension of seventeen inches and a lengthdimension of sixty-six inches, the films 12A-12E may have acorresponding width of fifteen inches, and corresponding length ofsixty-three inches. This provides sufficient spacing to form theabove-described interior channels 24. Simultaneously, the valve(s) aresealed to layer 11B at a lateral end. The invention is not limited tothese specific dimensions but may include any dimensions necessary toperform a desired function of the panel. As mentioned in a preferredembodiment, the films 12A-12E have smaller width or length dimensionsthan the envelope 11 for forming the channels 24.

As represented by the dashed line 32, the films 12A-12E are sealed toone another and to the first aluminum sheet 11A along the lateral edges33 of the films 12A-12E. This first seal 32 is disposed laterally fromthe edge 33 of the films 12A-12B. A second seal 34 is shown in FIG. 4B,and is disposed along the opposite edge 35 of the films 12A-12E spacedlaterally toward seal 32. Each of the seals 32 and 34 represent thesealing of the films 12A-12E to themselves and to sheet 11A along thoseareas where the polyethylene areas of respective layers or films are incontact. These steps of providing seals 32 and 34 are provided primarilyto align the films 12A-12E with one another and relative to sheets 11Aand 11B for assembly of the gas-filled panel. In addition, the seals 32and 34 do not form

With respect FIG. 4C, the larger rectangle represents the secondaluminum laminate sheet 11B positioned over the first sheet 11A and thefilms 12A-12E. The dashed rectangle represents the films 12A-12E belowthe sheet 11B, or sandwiched between both sheets 11A and 11B, and havingthe longitudinal edges 33 and lateral edges 35. Two seals 18A and 18Bare then formed along the length of the sheets 11A and 11B. As shown,the longitudinal seals 18A and 18B are disposed laterally inward of theedge 23 of the sheets 11A and 11B. However, relative to the longitudinaledges 33 of the films 12A-12E, the seals 18A and 18B are disposed towardedges 23 of the aluminum sheets 11A and 11B. Described in anothermanner, the seals 18A and 18B are disposed between edges 23 of thesheets 11A and 11B and edges 33 of the films 12A and 12E.

The sealing during these first three steps may be done usingsufficiently heated die presses that press against the films 12A-12E andsheets 11A and 11B for a sufficient time at a sufficient pressure toform the seals. For example seals may be sufficiently formed at about290° F. (±10° F.) for a dwell time of about 4.5 seconds (±1.00 seconds)at a pressure of about 25 lbs/in² to about 40 lbs/in².

With respect to FIG. 4D, there is shown final sealing steps whichinclude forming lateral end seals 36A and 36B and forming the pluralityof seals 34 formed along the films 12A-12E and sheets 11A and 11B thatare disposed perpendicular relative to the seals 18A and 18B. Inaddition, seals 36A and 36B are formed perpendicular to the seals 18Aand 18B, and between lateral ends 35 of the films 12A-12E and opposinglateral ends 37 of the sheets 11A and 11B. Note, the valve(s) 25A (25B)is any typical valve used for inflating items and has a blue dye orcoating along an inside surface to prevent the valve(s) 25A (25B) frombeing closed when seals 36A and 36B are formed.

In this step the films 12A-12E are adhered to one another and the sheets11A and 11B along the seals 34. As shown in FIGS. 1B and 2, the seals 34are formed at the gaps 27 between the metal stripes 15 to seal the films12A-12E to one another and to the sheets 11A and 11B. As shown, theseals 34 are spaced laterally inward relative to seals 18A and 18Bthereby forming the channel 24 between longitudinal edges 33 and 23 ofthe films 12A and 12B and sheets 11A and 11B, respectively. The sealingat this final step may be done using sufficiently heated die pressesthat are pressed against the films 12A-12E and sheets 11A and 11B for asufficient time at a sufficient pressure to form the seals. For exampleseals may be sufficiently formed at about 250° F. (±10° F.) for a dwelltime of about 4.75 seconds (±1.00 seconds) at a pressure of about 25lbs/in² to about 40 lbs/in².

With respect to FIG. 3 there is illustrated a die 19 prepared to pressseal the components of the panel for the final sealing step shown inFIG. 4C. In this particular step, it has been found to sufficiently sealthe components using the ribbed die 19. A platen 20 is used to supportthe films 12A-12E and sheets 11A, 11B during the sealing process. Morespecifically, a ⅛ ″-¼″ high temperature silicone sponge rubber layer 21is positioned over the platen 20, and a ¼″ epdm (ethylene propylenediene monomer) rubber or silicone 22 is positioned over the siliconelayer 21. The EPDM durometer measures 50A but can be altered based onthe film. In addition, a phenolic insulation 39 is positioned betweenthe platen 20 and a support table 38. The platen 20 is heated using aflexible heat tube. Such a platen assembly provides temperature controlof the sealing process so sealing is performed under aconsistent/uniform temperature and during repetitive impressions.

With respect to FIG. 5, there is shown a flow chart describing steps forassembling the inflatable panel. In a first step 40, the films 12A-12Bare positioned relative to one another so that the metal stripes 15 arealigned with gaps 27 of consecutive films 12A-12E so the films 12A-12Eadhere to one another and to the sheets 11A-11B when sealed. In step 42,the films 12A-12E are sealed relative to one another and the first sheet11A along lateral edges 23 of the films 12A-12E. This step 42 isperformed so that the stripes 15 and gaps 27 on the films 12A-12Emaintain alignment relative to one another during the assembly process.Simultaneously, the valve(s) are sealed to layer 11B at a lateral end.

Then in step 44, the valves 25A and 25B are tacked to the second sheet11B before both are sealed to the first sheet. With respect to step 46the second sheet 11B is sealed to the first sheet 11A between thelongitudinal edges 23 of films 12A-12E and the longitudinal edges 23 ofthe sheets 11A-11B and between the lateral edges 35 of films 12A-12E.With the longitudinal seals 18A and 18B formed, the valves 25A and 25Bis sealed to sheets 11A and 11B at a lateral end thereof as set forth instep 48. In step 48, the lateral seals 36 are formed between respectiveends 35 and 37 of the films 12A-12E and the sheets 11A and 11B, therebysimultaneously sealing the sheets 11A and 11B together, and the valves25A and 25B to the sheets 11A and 11B. With respect to step 50, theinternal films 12A-12E are then sealed to one another and to the sheets11A and 11B at the areas or gaps 27 between the metal stripes 15.

In reference to FIGS. 6 and 7, there is illustrated the platen 20 andthe use of the platen in assembling the panels 10. More specifically, inFIG. 6, there is shown an underside 52 of the platen 20. As shown, theplaten includes two undulating heating tubes 54A and 54B, each of whichis connected to a corresponding thermocouple 56A and 56B for heating theplaten 20 for practicing the above described sealing steps. Such aplaten 20 may be obtained from Watlow Electric Mfg. located in SaintLouis, Mo.

As shown in FIG. 7, in an embodiment two platens 20 are used side byside to assemble panels that are approximately seventeen inches wide andsixty inches long. The width for all the components shown in FIG. 7 isdesignated W and the length for all components is designated L. Each ofthe platens 20 is about thirty-seven inches long so the combined platensare about seventy four inches in length (L); and, each of the platens 20is about forty-eight inches wide. The layers 21 and 22 disposed betweenplaten 20 and panels 10 are preferably about the same length and widthof the combined platens 20.

In the particular illustration in FIG. 7, there is shown a final step inthe assembly of the panels 10A-10C in which seals 34 The panels 10A-10C,or materials for making the panels 10A-10C are moving in sheet/film formin the direction indicated by arrows 60 across the platens 20. The die19 (not shown) is about sixty-six inches in length and seventeen wide.The ribs 17 (see FIG. 3) that form the seals 34 are about fifteen incheslong, and the outermost ribs 28 (see FIG. 3) that form lateral seals 36Aand 36A are seventeen inches in length.

Again, with respect to FIG. 7, the die 19 was first pressed againstplatens 20 to form seals 34, 36A and 36B on panel 10C, and the sheets11A (not shown), 11B and films 12A-12E (not shown) are indexed in thedirection of arrows 60 to form panel 10B. In the next step, thematerials will be advanced or indexed so that panel 10A may be stampedaccordingly. As the panel 10A to be formed is positioned over theplatens 20, there be a heat transfer relative to the platens 20 andpanel 10A which has not been finally heated and sealed. In comparison,the panel 10C has been sealed and heated so the heat transfer betweenpanel 10C and the platens 20 may be of less concern. Accordingly, theheat tubes 54A may require heating independent of heat tubes 54B inorder to achieve a desired temperature within a sufficient amount oftime to meet production demands. In this manner the two platens 20provide four heating quadrants 62 each of which may be heatedindependent of one another to increase flexibility of assembly demands.

In this manner an inflatable or gas-filled insulation panel is providedthat has desirable temperature barrier and/or insulation properties. Thealuminum, including the aluminum laminate sheets, provides certainadvantages over inflatable or gas-filled insulation materials. Theexterior aluminum sheets 11A, 11B provides enhanced thermal performance,retains gases within the panel because the aluminum is less permeablethan other materials so oxygen cannot seep into the panel, displace thegas and provide exterior structural integrity. In use, the gas-filledpanel 10 may be used in combination with other insulation products suchas fiberglass insulation or the like, or by itself. In an exemplaryembodiment, the panels 10 may be placed over fiberglass insulation inbetween building frame members for wall frames, attics and the like. Thepanels 10 may be secured in place by frictional contact with parallelframe members. In another embodiment, for example in an attic, thepanels 10 may be disposed on top of insulation and disposedperpendicular to attic frame members, with an insulation material havingbeen placed between the attic frame members. As noted above, thedimensions of the panels 10 may vary according to applications. In oneembodiment in which the panels 10 are used in combination withfiberglass insulation for a building in which the fiberglass is about3.5 inches thick, the panels may be about 1.5 to about 1.8 inches inthickness.

The thermal performances of gas-filled panels (GFP) with internal andexternal reflective surfaces were measured in the Large-Scale ClimateSimulator (LSCS) at the Oak Ridge National Laboratory. Prototype panelsfilled with argon and panels filled with air were evaluated for bothwinter and summer conditions. The nominal 1.6-1.8 inch (38.1 mm) thickGFP were installed on top of nominal 3.5-inch (88.9 mm) thick fiberglassbatts, having a thermal resistance of value R 13 ft²·h·° F./Btu (RSI2.29 m2·K/W), to simulate retrofit attic insulation installation.Analysis of the experimental results provided the thermal resistance ofthe batts, the thermal resistance of the gas-filled panels, and theradiant barrier contributions to the overall thermal resistance betweenthe attic floor and the roof sheathing.

The first system consisted of nominal R 13 ft²·h·° F./Btu (RSI 2.29m2·K/W) fiberglass batts on the attic floor. The second system hadair-filled panels installed on top of the batts while the third systemhad argon-filled panels installed on top of the batts. The gas-filledpanels were installed perpendicular to the ceiling joists in both cases.The three systems were tested with the same thermal boundary conditionsto facilitate comparisons of the steady-state performances. Winterconditions included an outside temperature 25° F. (−3.9° C.) and insidetemperature 70° F. (21.1° C.). The summer conditions included an outsidetemperature of 115° F. (46.1° C.) and roof sheathing temperature of 150°F. (65.6° C.) due to simulated solar radiation. The thermal resistivityof the batt insulation and the gas-filled panels were evaluated usingASTM C 518 to provide supplementary data. See, “Standard Test Method forSteady-State Thermal Transmission Properties by Means of the Heat FlowMeter Apparatus”, 2006 Annual Book of ASTM Standards, Vol. 4.06 (2006)pp. 153-167.

The installation of both air-filled GFP and argon-filled GFP on top offiberglass insulation resulted in added thermal resistance in the atticspace during both summer and winter conditions. Three components of theincrease in attic thermal resistance were measured including the thermalresistance of the batt insulation, the gas-filled panel thermalresistance and the attic air thermal resistance.

TABLE I Thermal Resistance Contributions Summer Winter ContributionsArgon Air Argon Air GFP 5.6 5.9 4.5 4.6 Radiant Barrier 6.2 6.0 0.7 0.5Fiberglass batt change 0.5 0.6 0.2 −0.1   Total 12.3 12.5  5.4 5.0 Note:Panel Thicknesses: Argon 1.6 inches; Air 1.8 inches

The installation of air and argon gas-filled panels on top of fiberglassbatts resulted in a reduction in the operating temperature of the battsin the summer simulations with a resulting increase in the R-value ofthe batts of about 0.56 ft²·h·° F./Btu (0.099 m²·K/W), and a change inthe R-value of −0.20 ft²·h·° F./Btu (−0.04 m²·K/W) in the R-value forwinter conditions.

The argon gas-filled panel had R-value of about 5.6 ft²·h·° F./Btu (0.99m²·K/W) under summer conditions and an R-value of in the range 4.5ft²·h·° F./Btu (0.79 m²·K/W) under winter conditions. The air gas-filledpanel had an R-value in the range 5.9 ft²·h·° F./Btu (1.04 m²·K/W) undersummer conditions and an R-value of about 4.6 ft²·h·° F./Btu (0.81m²·K/W) under winter conditions. In addition, the argon gas-filledpanels increased attic thermal resistance by 6.16 ft²·° F./Btu (1.08m²·K/W). There was an increase in attic thermal resistance of 0.72ft²·h·° F./Btu (0.13 m²·K/W) under winter conditions. For air gas-filledpanels, there was an increase in the attic thermal resistance of about6.0 ft²·h·° F./Btu (1.05 m²·K/W) for summer conditions, and an increaseof about 0.46 ft²·h·° F./Btu (0.081 m²·K/W) for winter conditions. Thetotal of the previously listed contributions to the thermal performancewas about 12.3 to 12.5 ft²·h·° F./Btu (2.17 to 2.20 m²·K/W) for summerconditions; and, the overall contribution for simulated winterconditions on average was about 5.0 ft²·h·° F./Btu (0.88 m²·K/W).

In addition flammability testing was performed in accordance with ASTME-84, Standard Test Method for Surface Burning Characteristics ofBuilding Materials. The test resulted in a Class A rating with a FlameSpread less 25 and smoked developing rating less than 450.

While exemplary embodiment of the invention has been described withreference to an exemplary embodiment, it will be understood by thoseskilled in the art that various changes, omissions and/or additions maybe made and equivalents may be substituted for elements thereof withoutdeparting from the spirit and scope of the invention. In addition, manymodifications may be made to adapt a particular situation or material tothe teachings of the invention without departing from the scope thereof.Therefore, it is intended that the invention not be limited to theparticular embodiment disclosed as the best mode contemplated forcarrying out this invention, but that the invention will include allembodiments falling within the scope of the appended claims. Moreover,unless specifically stated any use of the terms first, second, etc., donot denote any order or importance, but rather the terms first, second,etc., are used to distinguish one element from another.

What is claimed is:
 1. A system for assembling an inflatable insulationpanel having an envelope with an outer reflective surface and aplurality of internal films, each film being of a polymeric material andhaving a plurality of reflective surfaces thereon and spaced apart,comprising: at least one heating platen for supporting a first andsecond sheet of laminated material, at least one of which includes theouter reflective surface and an inner polymeric surface, and theinternal films positioned between the first and second sheet, saidheating platen for providing heat to seal the films to one another andto the first and second sheets; an insulating layer positioned on theplaten disposed between the platen and the first and second sheets oflaminated material; and, a die press for applying pressure against thetwo sheets and films while the platen provides a source of heat whereinthe die includes a plurality of ribs having a plurality of internal ribsaligned with gaps in the films between the spaced apart reflectivesurfaces and two external ribs positioned outside the internal ribsalong the die press, parallel to the internal films, disposed atcorresponding ends thereof for forming lateral seals extending the widthof the panel at lateral ends of the panel.
 2. The system of claim 1,wherein the die applies a pressure of about 25 lb/in² to about 40 lb/in²and the platen is heated to a temperature of about 250° F., both for adwell time of about 4.75 seconds.
 3. The system of claim 1, wherein theheating platen includes a plurality of quadrants the temperature of eachquadrant can be controlled independent of one another.
 4. The system ofclaim 1, wherein a width of the first and the second sheet is greaterthan a width of the internal films based on lateral edges of the firstand second sheets being positioned outside lateral edges of the internalfilms.
 5. The system of claim 4, wherein the internal ribs form lateralseals along the insulation panel between the lateral edges of theinternal films and that the external ribs form lateral seals along theinsulation panel between the lateral edge of the internal film and thelateral edge of the first or second sheet.
 6. The system of claim 1,wherein the insulating layer comprises: a first silicone rubber layerdisposed between the platen and the first and second sheets of laminatedmaterial; and a second silicone rubber layer disposed between the firstsilicone rubber layer and the first and second sheets.
 7. The system ofclaim 6, wherein the first silicone rubber layer is a high temperaturesilicone sponge rubber layer with a thickness in a range between ⅛″ and¼″, and wherein the second silicone rubber layer is an ethylenepropylene diene monomer rubber with a thickness of ¼″.
 8. The system ofclaim 7, wherein a diameter measurement of the ethylene propylene dienemonomer rubber of the second silicone rubber layer is 50 A.
 9. A platenassembly for assembling an inflatable insulation panel having anenvelope with an outer reflective surface and a plurality of internalfilms, each film being of a polymeric material and having a plurality ofreflective surfaces thereon and spaced apart, said platen assemblycomprising: at least one heating platen for supporting a first andsecond sheet of laminated material, at least one of which includes theouter reflective surface and an inner polymeric surface, and theinternal films positioned between the first and second sheet, saidheating platen for providing heat to seal the films to one another andto the first and second sheets; a first insulating layer positioned onthe platen disposed between the platen and the first or second sheetswherein the first insulating layer comprises a first silicone rubberlayer disposed between the platen and the first or second sheets and asecond silicone rubber layer disposed between the first silicone rubberlayer and the first or second sheets; a second insulating layerpositioned between the heating platen and a support table below theheating platen; and a die press for applying pressure against the twosheets and films while the platen provides a source of heat wherein thedie includes a plurality of ribs having a plurality of internal ribsaligned with gaps in the films between the spaced apart reflectivesurfaces and two external ribs positioned outside the internal ribsalong the die press, parallel to the internal films, disposed atcorresponding ends thereof for forming lateral seals extending the widthof the panel at lateral ends of the panel.
 10. The system of claim 9,wherein the die applies a pressure of about 25 lb/in² to about 40 lb/in²and the platen is heated to a temperature of about 250° F., both for adwell time of about 4.75 seconds.
 11. The system of claim 9, wherein theheating platen includes a plurality of quadrants the temperature of eachquadrant can be controlled independent of one another.
 12. The system ofclaim 9, wherein a width of the first and the second sheet is greaterthan a width of the internal films based on lateral edges of the firstand second sheets being positioned outside lateral edges of the internalfilms.
 13. The system of claim 12, wherein the internal ribs formlateral seals along the insulation panel between the lateral edges ofthe internal films and that the external ribs form lateral seals alongthe insulation panel between the lateral edge of the internal film andthe lateral edge of the first or second sheet.
 14. The system of claim9, wherein the heating platen comprises a flexible heat tube configuredto provide the source of heat at a controlled temperature such that theapplication of pressure from the die press is applied at a uniformtemperature during repetitive impressions.
 15. The system of claim 9,wherein the heating platen comprises a pair of heating tubes on anunderside of the platen, said heating tubes connected to a respectivethermocouple.
 16. The system of claim 9, wherein the first siliconerubber layer is a high temperature silicone sponge rubber layer with athickness in a range between ⅛″ and ¼″, and wherein the second siliconerubber layer is an ethylene propylene lene monomer rubber with a.thickness of ¼″.
 17. The system of claim 16, wherein a durometermeasurement of the ethylene propylene diene monomer rubber of the secondsilicone rubber layer is 50 A.